Repair station for component insertion device

ABSTRACT

A repair station located at the insertion head of an electrical component assembly machine, the repair station permitting the testing and placement of components into the sequence of components to be inserted into printed circuit boards.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a repair station for testing and placing insequence missing components in a sequence of components to be insertedinto a printed circuit board.

2. Summary of the Prior Art

It has been conventional in the process of automatically assemblingaxial lead electrical components to printed circuit boards to have aplurality of taped series of identical components aligned on a machinewhich removes the components from the tape and places them in apredesigned sequence on a conveyor. The conveyor then transports thecomponents through a retaping station so that components are taped inthe desired sequence for insertion into the board. A machine of thislatter type is illustrated in commonly owned U.S. Pat. No. 4,119,206.Thereafter, the taped roll of sequenced components is placed on aninsertion machine which removes the components from the tape, bends thecomponent leads and inserts the leads down through preselected openingsin the printed circuit board. A cut-clinch unit located beneath theboard cuts off excess lead wire and bends the wire over to physicallyfasten the component to the board. Machines of this latter type areillustrated in commonly owned U.S. Pat. Nos. 4,080,730 and 4,403,390.

It is desirable, however, to combine the functions of the sequencing andinserting machines into a single machine. U.S. Pat. No. 3,455,493illustrates a machine of this latter type.

SUMMARY OF THE INVENTION

It is an object of this invention to provide a combined sequencing andinsertion machine in which a conveyor receives components fromdispensers which remove components from a taped series in apredetermined sequence, the conveyor delivers the sequenced componentsat a transfer station to another conveyor which transports thecomponents to an insertion head which bends the component leads andinserts the leads into preselected openings in a printed circuit board.A cut-clinch unit then attaches the component to the board.

It is still a further object of this invention to provide two drivemodes between a sequencing conveyor and conveyor for transportingcomponents to an insertion head, one drive mode permitting the conveyorsto be operated in timed relation while a second drive mode permits theconveyors to be operated independently. In the first drive mode, thedrive to the sequencing conveyor drives the transport conveyor and inthe second drive mode, the drive to the insertion head drives thetransport conveyor. The first drive mode is to recharge the transportconveyor and the second drive mode is the automatic indexing whileinserting components into the printed circuit board.

It is another object of this invention to provide in a combinedsequencing and inserting machine a component repair and test station atthe insertion head which permits the operator to insert into a sequenceof components a missing component resulting from a component testinginadequate at the sequencer or failing to be properly transferredbetween the sequencer and the inserter.

It is a further object of this invention to provide a combined componentsequencing and insertion machine wherein the components are bodycentered and lead trimmed at the sequencing station and lead centeredand lead trimmed at the insertion station.

It is also an object of this invention to provide a combined componentsequencing and insertion machine wherein the components are tested andfaulty components removed at the sequencing station, and faultycomponents replaced at the insertion station.

It is another object of this invention to provide a component inspectionstation downstream from a transfer station positioned between asequencing station and insertion station of a combined axial leadcomponent sequencing and insertion machine.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of the combined sequence and inserting machineof this invention;

FIG. 2 is an exploded perspective view of the drive between thesequencer and the transport conveyor;

FIGS. 3a to 3b are views illustrating the body centering and leadtrimming mechanism;

FIGS. 4a to 4c are views illustrating the various positions of thecomponent while passing through the body centering and lead trimmingmechanism;

FIG. 5 is a perspective view of the transport conveyor;

FIG. 6 is a side elevational view of the details of the insertion headdrive for the transport conveyor; and,

FIGS. 7 to 9 are views of the repair station.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Attention is directed to FIG. 1 which illustrates side by side freestanding sequencing machine 10 and inserting machine 12. The sequencingmachine is of the type illustrated in U.S. Pat. No. 4,119,206 andincludes a base 14 supporting a driven conveyor 16 which receivescomponents from dispensers 18 which remove components from taped reels(not shown) in a predetermined sequence and place the components on theconveyor. The components are passed through a verifier 20 to determinethe acceptability of the component. Unacceptable components are blownoff the conveyor by blower 25 leaving a blank space in the sequence.Also, if there is a component missing in the sequence at the verifier,the machine will stop so the operator can inspect for faults in thesequencer.

Thereafter, the components pass through the transfer station 22 onto thetransport conveyor 24 which conveys the components to the insertionmachine. The insertion machine is of the type illustrated in U.S. Pat.Nos. 4,080,730 and 4,403,390 and has a base 26 supporting an insertionhead 28 which receives the components, forms the leads into a stapleshape and inserts the leads into preselected openings of a printedcircuit board which is carried on the assembly table 30 of the insertionmachine. Located downstream from the transfer station 22 is aninspection station 32 which will tell the machine control the locationof missing components in the sequence occurring from components notbeing properly transported through the transfer station 22. If aninadequate component was removed at the verifier, the machine controlwill tell the inspection station that a blank space in the sequence iscoming and should be ignored. If, however, a component does not properlypass through the transfer station, the inspection station will noticethe absence of the component and stop the machine so the operator cancheck for a jammed area, for example, in the transfer station. Themachine control will automatically stop the entire combined machine whenthe missing component in the sequence reaches the repair station 34located at the operator's station 36 at the insertion head 28. Further,the machine control will designate to the operator the particularcomponent that must be replaced and the operator can then test andreplace the missing component into the sequence of components to beinserted into the board, as will be described hereinafter.

In the operation of the combined machines, there are two drive modes,one in which the sequencer 10 and the transport conveyor 24 are drivenby the sequencer drive mechanism and the other drive mode in which thetransport conveyor 24 is indexed by the insertion head independently ofthe sequencer drive mechanism. The purposes of the first drive mode isto recharge the transport conveyor 24 with components during machine setup. The second drive mode is the normal automatic indeixng of thetransport conveyor 24 as the insertion head removes components from thetransport conveyor 24 and automatically inserts the components into theprinted circuit board.

Attention is now directed to FIG. 2 which illustrates the common drivemechanism 38 for the sequencer 10 and the transfer station 22 which isused to load up an empty transport conveyor 24. A motor 40 drives a gearbox 42 which has an output drive 44 to the verifier of the sequencingmachine and an output drive 46 to drive both the sequencer 10 and theconveyor 24. The conveyor 24 comprises a pair of timing belts 101retained in tracks 98 and each timing belt has clips 48 for receivingthe component leads. The conveyor 24 will be described in greater detailhereinafter.

A drive belt 50 drives a shaft 52 which drives the chain 54 of theconveyor 16. The components (C) are deposited on the conveyor chain 54by the dispensers 18. The conveyor chain 54 passes the componentsthrough the verifier 20 which has a blow-out station 25 which removesinadequate components from the chain 54.

FIGS. 3a and 3b and 4a to 4c illustrate the sequence of the componentbeing passed through the body centering fingers 56, the leads (L) beingtrimmed and the component being deposited in the clips 48.

As the components (c) are carried along in the cavity 55 of thesequencer conveyor chain 54, they approach the driving cutter wheels 57which have shoulders 58 which contact the component leads (L) and raisethe leads out of the cavity 55 so that the component is supported on theshoulders 58 of the wheels 57. (See FIG. 4a). Thereafter, the componentbody (b) passes through the centering fingers 56 which center thecomponent body (b) between the wheels 57. The downward load of thefingers 56 is resisted by the undersurface of the component leads (L)being supported by the arcuate uprights 59' of the support 59 carried onthe machine frame (not shown). As the component passes through the ends60 of the fingers 56, the leads are trimmed between the shoulders 58 ofwheels 57 and the outboard small cutter wheels 61. (See FIGS. 4a and4c). The shoulders 58 and arcuate uprights 59' are taken from differentcenter lines and after the leads are trimmed, the shoulders 58 drop awayfrom the surface 59 and the component body (b) is dragged along surface59 by the uprights 62 of the chain 54. Pivotally supported on the cutterwheel shaft 63 is a door 64 (see FIG. 4) which contacts the uppersurface on the component leads so that the leads are retained betweenthe door 64 and surface 59' as it is pushed along by the uprights 62.Thereafter, the component leads are positioned down into the clips 48and the door 64 closes above the component leads to prevent thecomponents from falling out of the clips. (See FIG. 4b). At this time,the uprights 62 which are pivoted at 66 fall off cam 66' and pass by thecomponent leads so that the leads are securely positioned in the clips48 without being bent during the transfer from the sequencer to thetransport conveyor 24.

The shaft 52 drives a belt 68 coupled to the free wheeling disc 70 ofthe clutch 72. The opposite side 74 of clutch 72 is keyed to the shaft76 which drives the conveyor 24. Mounted on a bracket 78 is a cylinder80 secured to the yoke 82 controlling the position of clutch member 74.The clutch member 74 has slots 86 and cylinder 80 will slide clutchmember 74 on shaft 76 to engage the pins 84 in slots 86 to drivinglycouple shaft 52 to shaft 76 to drive the conveyor 24. In the movement ofthe cylinder 80, the cylinder bottoms out in both directions whichdetermines the stroke of clutch member 74. If the clutch member 74 hasnot properly moved in the desired direction, limit switches 88 will notbe activated to tell the machine control the clutch is properlyoperating. In the above described recharged mode where it is desirableto get components to the head quickly, the clutch 72 is engaged tocouple the drive to the sequencer chain and the drive to the transferconveyor together. An interupter disc 73 carries indication 75 read byphoto cell 77 to tell the machine control when the conveyors 16 and 24are synchronized on machine setup.

Attention is now directed to FIG. 5 which illustrates details of thetransport conveyor 24. The tracks 98 comprise a pair of opposed guides95 mounted to the machine frame. The guides 95 comprises upper and lowerelongated housings 97, 97' having spaced opposed openings 99 for receiptof the component leads. Carried in the guides 95 are timing belts 101 onwhich clips 48 are mounted. As the belts 101 are driven, the clips 48retain the leads (e) and the leads are received in the openings 99 withtheir ends adjacent the shoulders 103 of housings 97 so the leads arelaterally retained while being transported normal to their longitudinalaxis. Also, the upper lip 105 of the housing 97 keeps the component fromfalling out of the clips while being carried along by the clips 48.

Attention is now directed to FIGS. 1, 6, and 8 which illustrate theoperation of the insertion head 28 and the drive for the belts 101during the automatic insertion operation. The components (c) are carriedby the belts 101 to a position above the insertion head. The belts 101then travel downwardly and under the insertion head around sprockets 107carried on shafts 121. The components pass through a guide chute 100which has lead centering surfaces 116 which center the components andpositions the components for lead trimming, forming and inserting by thehead tooling 102. (See FIG. 8). The components are taken off the end 114of chute 100 by clips 48 and positioned on shear block 109. Thereafter,the upper shear block 111 trims the leads and the scrap is carried byclips 48 off the shear block 109 and it (See FIG. 8) and falls down ramp113 into a collection bin 115.

The insertion head 28 is operated by the cylinder 104 which pivots thearm 106 of linkage 108 attached to the insertion head. The arm 110 oflink 108 drives indexing mechanism 117 which indexes the sprocket 107 todrive the timing belts 101. As the insertion head moves down, the arm110 is pivoted upward causing pin 91 to move in slot 93 of housing 119against the bias of spring 127. The bottom 123 of arm 117 carries link125 connected to shaft 133 through a one way clutch (not shown). As theinsertion head is lowered, the arm 117 is moved upward and the link 125strikes stop 129. At this time, the clutch 72 is disengaged and thesolenoids 135 and 90 (FIG. 2) are engaged to lock the shafts 121 and theshaft 76. There are two shafts 121 and two solenoids 135 one located oneach side of the head. Also, in the sequence of operation, the sequencerat this time is depositing a component into the next stationary clip 48in the sequence at the transfer station. The solenoids 135 and 90 eachhave rollers 92 which engage star wheels 96 on the shafts 121 and 76 tolock the shafts in fixed positions, with a pair of clips 48 positioninga component directly under the insertion head tooling.

As the insertion head is raised, the arm 110 will be lowered until thepin 107 bottoms out in slot 93 which will move arm 117 downward rotatinglink 125 clockwise (FIG. 5). At this time, the solenoids 90 and 135 aredisengaged removing rollers 92 from star wheels 96 leaving the shaft 74and shafts 121, free to rotate. The link 125 drives gear 131 through aone way clutch (not shown) on shaft 133 and indexes gear 139 on shafts121 counter clockwise one incremental spacing of clips 48 to placeanother component under the insertion head. The shaft 133 is carried ona link 141 pivoted at 142 on the head casting 143. A tension spring 145is secured between the link 141 and the head casting to bias gear 131toward gear 139 to obtain zero blacklash there between. An adjustablestop 151 limits the pivotal movement of the link 141 and permitsaccurate adjustment of the drive between gear 131 and gear 139.

Reference is now made to FIGS. 7 to 9 which illustrate the chute 100 andthe repair station 34. The components are moved through the chute 100 bythe clips 48 (see FIG. 5) until they are carried off the end 114 of thechute by the clips 48 and onto the shear block 109 of the insertion headtooling 102.

Located in the chute 100 is the repair station 34 which comprises a door118 slidably disposed on the sides 120 of the housing 122 attached tothe chute 100 by bolts 124. When a blank occurs in the sequence, themachine will stop with the empty clips 48 in front of the slots 126 (SeeFIG. 7) in the repair station. The machine control will tell theoperator the component to select and the operator will place thecomponent on the shelfs 120 and in the relieved areas 128 of drive wheel130. As the door is withdrawn from the closed position, the racks 132engage the teeth 134 on wheels 130 rotating the wheels 130 passing thecomponent leads through the contacts 136, 138 to test the component. Ifthe component test adequate, then the door can be further withdrawn andthe wheels 130 rotated to dump the component leads into the slots 126.At this position, the component is in front of the leading edge 157 ofthe door 118. As the door is inserted and closed, the leading edge 157places the component leads into the clip 48. Also, the leading edge 157of door 118 closes the gap 159 in the track formed by slot 126. If thereplacement component does not test adequate, the door is returned tothe closed position; and by removing the component, another replacementcomponent can be tested.

In the above manner, a separate sequencing and inserting machine can beused together to verify components, body center and lead trimcomponents, inspect for missing components and repair the sequence ofcomponents at the operator's station at the insertion head.

We claim:
 1. An axial lead electrical component insertion machine forinserting such components into a printed circuit board comprising:acomponent conveyor including a plurality of spaced clip means forreceiving different components in a selected sequence; means forverifying that each conveyed component is within its designspecification; means for removing a component from its clip means whenit is not so verified, leaving an empty clip means; means forpositioning said empty clip means at a predetermined location, and arepair station for inserting a correct component into said empty clipmeans located at said predetermined location, including:a doorretractable from a load position through a test position to a retractedposition and advanceable from said retracted position through said testand load positions to an advanced position; rack means including a racksecured to said door; drive wheel means including a gear driven by saidrack; slot means defined in said drive wheel means for supporting acomponent, said slot means being located to receive a component whensaid door is at said load position; test means for testing the supportedcomponent when said door has been retracted to said test position; guidemeans for guiding a component placed thereon to the empty clip meanslocated at said predetermined position; said slot means beingselectively located when said door is at said retracted position todeposit the tested component on said guide means; said rack meansincluding a pusher at the forward end of said rack and selectivelylocated rearwardly of the component as it is deposited on said guidemeans, said pusher pushing the component into said empty clip means assaid door is displaced to said advanced position.
 2. An insertionmachine according to claim 1 wherein said drive wheel means comprises apair of spaced gears and said slot means is defined in said gears andreceives the leads of said component.
 3. An insertion machine accordingto claim 2 wherein said repair station further comprises a housinghaving opposed grooves for receiving the sides of said door.